Patent Application
20190145011
The present disclosure generally relates to an apparatus which is a combination corrosion inhibitor and corrosion indicator. More particularly, the disclosure generally relates to a corrosion inhibition apparatus including an indicator which notifies when a sacrificial anode requires replacement and facilitates rapid replacement of expiring components.
In complex systems where sea water or other electrolytically active fluids come in common contact with components of a metal system, electrolytic corrosion can become a root cause of component failure in all metal components including, but not limited to heat exchangers, engines, generators, pumps, piping, and other connected apparatus. The corrosion of any component can result in structural failure, subsequent leakage of system components, and or contamination between the fluids and may cause component and or system failure.
The source of corrosion may be a result of the electrochemical oxidation of metals reacting with an oxidant or fluid. Aqueous corrosion may result from an electrochemical reaction associated with differences in electrical potentials of two different, electrically connected metals which share contact with a common aqueous fluid. The two different metals may be referred to as an active metal and a noble metal. Ions of noble metals are more strongly bound to a surface of the noble metal than the ions of active metals. Given two or more metallic components all connected to each other and an aqueous solution the least noble metal will experience corrosion first. Examples of aqueous media, also referred to generally as electrolytes, may include, but are not limited to, solutions of salt water, acids, bases, or salts, certain gases at high temperatures, molten salts, or combinations thereof.
The corrosion avoidance strategy of supplying a sacrificial, less noble metal is often used to protect the more noble components in a system which interacts with electrolytically active fluids. The strategy only works if there is less noble, non-critical, active metal available to give up its electrons and is in continuous electrical contact with the system requiring protection. Once the sacrificial anode is exhausted the normal system components begin electrolytic corrosion at a comparatively accelerated rate on the next least noble components.
It is common practice to attach an active metal as a sacrificial anode to a more noble metal to reduce or eliminate electrolytic corrosion of a system comprising of numerous metal components. Continuous metallic contact and timely replacement of a depleted sacrificial anode is essential to the effectiveness of the sacrificial anode corrosion reduction strategy. The rate of electrolytic corrosion varies widely based on the conditions of the aqueous solution, proper grounding and the surrounding metallic structures. Failure to properly monitor the corrosion rate of the sacrificial anodes, replacing them prior to exhaustion can result in premature corrosion of the affected components and or system.
A corrosion inhibitor device or apparatus of that would facilitate visual monitoring of the sacrificial anode whether the system is dormant or operational and would allow for easy replacement of the sacrificial anode if visually determined to be necessary and would be beneficial to the sacrificial anode corrosion strategy.
In some embodiments, a visual electrolytic corrosion indication and prevention apparatus may include provisions for mounting an in-stream, continuous contact, continuously visible sacrificial anode, and visual indicator in a fluid passage. The apparatus may allow for the electrolytic corrosion protection of heat exchangers, engines, generators pumps and other metallically-connected systems components that share contact with electrolytically active fluids. The apparatus may consist of a collar body with a viewing port, collar adapter, system adapter, continuous contact in-line sacrificial anode, visual indicator, containment screen, site glass and compression seals. The compression seals may seal the apparatus components causing corrosive fluids to flow past a sacrificial anode while flowing through and contained by the apparatus. The sacrificial anode may be kept in continuous metallic contact with the apparatus via a spring, and or with hydraulic pressure plate which may be incorporated into the apparatus. The assembled combination of a collar adapter, spring, visual indicator, sacrificial anode, and site glass contained within the body collar when coupled to the base adapter may facilitate continuous visual inspection of the anode through a site glass without system shut down or disassembly. In some embodiments, the spring and visual indicator assembly may insure continuous metallic connection between either collar or system adapters and sacrificial anode which may fill the collar body view-ports with a bright indicator as the anode dissolves and the spring expands moving the coupled visual indicator progressively across the viewport. The apparatus may improve inspection, replacement and effectiveness of sacrificial anodes in electrolytically corrosive environments while facilitating rapid changing of sacrificial anode components without disassembly of flexible hose or rigid piping systems.
In some embodiments, the apparatus includes a collar body with viewports, or is itself transparent, a collar adapter, a system adapter, a sacrificial anode, and a spring coupled visual indicator and may be configured to include a containment screen on the inner diameter of the sacrificial anode. The collar body may include a first end and a second end. The collar adapter may be an internal fit into the collar body and couples, during use, to a first conduit. The collar adapter may be sealed inside the first end of the collar body and may be used alternatively as an inlet side or outlet and the base adapter as the alternate either connecting to the system to be protected. The system adapter may couple during use to a second conduit. The sacrificial anode may be positioned at least partially between the collar adapter and the base adapter. The sacrificial anode may include an opening in fluid flow during use, with the first conduit and the second conduit. The visual indicator may be positioned at least partially between the sacrificial anode and the collar adapter. The visual indicator may provide, a visual gauge regarding the extent of disintegration of the sacrificial anode. Mechanically the visual indicator is coupled to the spring, and may act as a bearing plate separating the spring from the sacrificial anode, evenly applying the spring force against the sacrificial anode, and may if configured may include a flow orifice that applies hydraulic pressure on the sacrificial anode.
In some embodiments, the first conduit and the second conduit are part of a single conduit and/or single assembly.
In some embodiments, the apparatus may include an elastically compressed member positioned between the collar adapter and the visual indicator. The elastically compressed member may apply pressure against the visual indicator that is in direct contact with the sacrificial anode. The elastically compressed member may apply pressure against the visual indicator and the sacrificial anode insuring direct metallic contact with the collar and or system adapter.
In some embodiments, a transparent containment member is positioned inside the collar body in or adjacent to one or more openings in the collar body. In some embodiments, at least a portion of the collar body is transparent or contains a viewport such that as the sacrificial anode dissolves and the spring coupled to the visual indicator expands moving the visual indicator down the axis of flow, progressively blocking the viewport. In some embodiments, the brightly colored visual indicator is visible through the collar body viewports and progressively fills the window as it moves down the axis as the sacrificial anode disintegrates.
In some embodiments, the apparatus may include one or more seals to inhibit fluids from leaking out of the apparatus during use. A first seal may be positioned between the collar adapter and the site glass and a second seal positioned between the site glass and the base adapter. The seals may be enabled by the compressive force exerted on the internal components and seals when the collar body is threaded onto the base adapter.
In some embodiments, the collar adapter is nested within the collar body sharing an axis uncoupled to allow independent rotation around the shared axis or as one part which connects to the system or conduit. In some embodiments, the base adapter is coupled to the collar body via thread or be pressed together and acting to close and seal the apparatus by coupling with the second end of the collar body 110b. In some embodiments, the system adapter may be inhibited from moving within the collar body by the site glass and collar adapter and seals contained within which share the same axis of compression within the containment vessel.
In some embodiments, a method of inhibiting corrosion may include conveying a corrosive fluid through a first conduit and through a collar adapter disposed at a first end of a collar body of the apparatus. The method may include conveying the corrosive fluid through an opening of a sacrificial anode and a visual indicator positioned at least partially between the collar adapter and a system adapter disposed at a second end of the collar body. The method may include conveying the corrosive fluid through the system adapter and subsequently through a second conduit coupled to the system adapter. The first conduit and the second conduit may form a part of a system. The method may include an elastically compressed member applying pressure against the visual indicator and the sacrificial anode such that the sacrificial anode remains in direct contact with the apparatus which in turn is connected to the component or system to be protected. The method may include providing a visual indication of the disintegration of the sacrificial anode using the visual indicator as seen through the viewports. The method may include inhibiting corrosion of at least a portion of the system using the visual electrolytic corrosion indication apparatus to replace depleted embodied sacrificial anode in a timely fashion. The method may give an indication of system wide corrosion of non-visual anodes throughout the system, thus helping to indicate the possibility of system anode depletion in addition to component corrosion (e.g., if whole system is grounded). For example in some systems there may be multiple sacrificial anodes in place to protect the system, many of which may not be visible. Using the herein described apparatus may allow one to determine the decomposition of sacrificial anodes which are not visible but installed in the same system (and/or at least a system which is coupled fluidically to the apparatus). One may determine the extent of decomposition of the unseen sacrificial anodes by observing the changing decomposition rate of the sacrificial anode of the apparatus.
In some embodiments, a method of inhibiting corrosion may include the ability to change all internal components of the apparatus by loosening the collar body and sliding it clear of the internal components all of which can then be removed and replaced individually or as an assembly. The method does not require dis-assembly movement or adjustment of either base adapter or collar adapters or the first and second conduits to which they are connected.
Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). The words “include,” “including,” and “includes” indicate open-ended relationships and therefore mean including, but not limited to. Similarly, the words “have,” “having,” and “has” also indicated open-ended relationships, and thus mean having, but not limited to. The terms “first,” “second,” “third,” and so forth as used herein are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.) unless such an ordering is otherwise explicitly indicated. For example, a “third die electrically connected to the module substrate” does not preclude scenarios in which a “fourth die electrically connected to the module substrate” is connected prior to the third die, unless otherwise specified. Similarly, a “second” feature does not require that a “first” feature be implemented prior to the “second” feature, unless otherwise specified.
Various components may be described as “configured to” perform a task or tasks. In such contexts, “configured to” is a broad recitation generally meaning “having structure that” performs the task or tasks during operation. As such, the component can be configured to perform the task even when the component is not currently performing that task (e.g., a set of electrical conductors may be configured to electrically connect a module to another module, even when the two modules are not connected). In some contexts, “configured to” may be a broad recitation of structure generally meaning “having circuitry that” performs the task or tasks during operation. As such, the component can be configured to perform the task even when the component is not currently on. In general, the circuitry that forms the structure corresponding to “configured to” may include hardware circuits.
Various components may be described as performing a task or tasks, for convenience in the description. Such descriptions should be interpreted as including the phrase “configured to.” Reciting a component that is configured to perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112 paragraph (f), interpretation for that component.
The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of this application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.
It is to be understood the present invention is not limited to particular devices or particular fluid systems, which may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise. Thus, for example, reference to “a linker” includes one or more linkers.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.
The term “connected” as used herein generally refers to pieces which may be joined or linked together.
The term “coupled” as used herein generally refers to pieces which may be used operatively with each other, or joined or linked together, with or without one or more intervening members.
The term “direct” or “directly” as used herein generally refers to one structure in physical contact with another structure, or, when used in reference to a procedure, means that one process effects another process or structure without the involvement of an intermediate step or component.
The term “noble metal” as used herein generally refers to a metal that resists chemical action, does not corrode, and is not easily attacked by acids or is the most noble in a collection of connected dissimilar metals.
The term “sacrificial anode” as used herein generally refers to a galvanic anode and is typically part of a galvanic cathodic protection (CP) system used to protect metal structures from corrosion. Sacrificial anodes are made from a metal alloy with a more “active” voltage (more negative reduction potential more positive electrochemical potential) than the metal of the structure. The difference in potential between the two metals means that the galvanic anode corrodes, so that the anode material is consumed in preference to the structure.
The term “elastically compressed” as used herein generally refers to a material such as a spring that stores energy in the form of elastic deformation which exerts pressure on the structures compressing its size. The pressure applied by the elastically compressed member will act to insure positive contact directly between the sacrificial anode and the adapters.
The term “site glass” as used herein generally refers to a portion of some embodiments of an apparatus described herein. At least portions of the site glass may be transparent. The site glass may be formed from any transparent material including glass or plastics.
In some embodiments, the apparatus 100 includes a collar body 110, a collar adapter 120, a sacrificial anode 140, an anode indicator 150, an elastically compressed member 170, and a system adapter 130.
In some embodiments, the sacrificial anode 140 and the visual indicator 150 may include opening 140a and opening 150a (e.g., as depicted in
Many current sacrificial anodes are designed and/or implemented in such a way as to protrude into a flow of a fluid flow resulting in a drop in pressure of a flow stream. In some embodiments, the sacrificial anode may include an opening extending through the collar body of the sacrificial anode. The opening allows a corrosive fluid to flow through the sacrificial anode and the apparatus. In some embodiments, the opening of the sacrificial anode may be dimensioned such that the sacrificial anode does not cause a drop in pressure of a flow stream of the corrosive fluid. For example, the sacrificial anode may be dimensioned such that the sacrificial anode does not protrude into the flow of the fluid flow stream but rather lines the circumference of the flow path. The nature of the exposure of the anode on the walls of the tube may reduce abrasive removal of anode material while maximizing the surface area exposed to the fluid stream.
In some embodiments, the anode may be protected by a containment screen 400.
In some embodiments, the containment screen may reduce or inhibit the resulting uneven surface of the sacrificial anode from disturbing the flow of the fluids as the sacrificial anode dissolves during use. The containment screen may inhibit the pressure from the flow of the fluid from prematurely dissolving the sacrificial anode, effectively holding the sacrificial anode in position as the anode.
In some embodiments, the containment screen may be formed from a material which is chemically inert or at least resistant to the environment the screen is exposed (e.g., the fluids flowing through the apparatus). The containment screen may be formed from, for example, stainless steel or certain plastics. The containment screen may be in the shape of a hollow tube or conduit which has a similar diameter to the opening extending through the apparatus. The containment screen may include a number of openings 410 or perforations extending through the screen to allow the fluids access to the sacrificial anode. The containment screen (e.g., along with the elastically compressed member, visual indicator, and/or sacrificial anode) may be such that they are easily removable and replaced as needed (i.e., typically when the sacrificial anode is replaced after having mostly or totally dissolved).
In some embodiments, a sacrificial anode may be formed from a more active metal or a less noble metal relative to any metal parts of a system which are desired to be protected. The sacrificial anode may be formed from, for example, magnesium, aluminum, and/or zinc. Magnesium has the most negative electro-potential of the three and is more suitable for areas where the electrolyte (soil or water) resistivity is higher. In some cases, the negative potential of magnesium can be a disadvantage: if the potential of the protected metal becomes too negative, hydrogen ions may be evolved on the cathode surface leading to hydrogen embrittlement or to disbonding of the coating. Zinc and aluminum are generally used in salt water, where the resistivity is generally lower. Zinc is considered a reliable material, but is not suitable for use at higher temperatures, as it tends to becomes less negative; if this happens, current may cease to flow and the anode stops working. Zinc has a relatively low driving voltage, which means in higher-resistivity soils or water it may not be able to provide sufficient current. However, in some circumstances (e.g., where there is a risk of hydrogen embrittlement) this lower voltage is advantageous, as overprotection is avoided. Aluminum anodes have several advantages, such as a lighter weight, and much higher capacity than zinc. However, aluminum's electrochemical behavior is not considered as reliable as zinc, and greater care must be taken in how aluminum anodes are used. Since the operation of a galvanic anode relies on the difference in electropotential between the anode and the cathode, practically any metal can be used to protect some other, providing there is a sufficient difference in potential. For example, iron anodes can be used to protect copper.
In some embodiments, the collar body may act as structural coupler and a containment vessel of the apparatus (e.g., as depicted in
In some embodiments, the collar adapter 120 (or system adapter 130) may include features which facilitate assembly/disassembly of the corrosion inhibition apparatus. For example, the collar body or either adapter may include one or more openings 125 which allow, for example, a spanner wrench to engage the adapters and or body collar body to gain leverage to remove the collar body. The collar body and either adapter may include one or more faces 127 which allow for a tool (e.g., a wrench) to engage the adapters such that a user may gain more leverage to facilitate disassembly of the apparatus.
Threading or other similar coupling means may allow rapid changing of sacrificial anode without disconnecting a conduit or other fixed plumbing from the system. This simple screw mechanism effectively seals the fluid while minimizing the disruption of hose or piping connections and plumbing. This configuration allows the apparatus to be disassembled without disconnecting the inlet or outlet conduits, by unscrewing the collar body from the collar adapter. This method prevents the necessity of disassembling the first or second conduit whether fixed or flexible and makes replacement of the sacrificial anode, spring, visual indicator and site glass without disconnecting the apparatus from either conduit.
In some embodiments, the sacrificial anode may be positioned in the collar body of the apparatus. The sacrificial anode may be positioned adjacent to the collar adapter such that the sacrificial anode is in direct and constant contact with the collar adapter. It is important to ensure continuous direct metallic contact between the sacrificial anode and the apparatus and that either or both adapters are metallically connected to the device to be protected.
In some embodiments, the apparatus may include a site glass 200.
In some embodiments, a first seal 210a (e.g., an o-ring) may be positioned between the collar adapter 120 and the site glass 200. In some embodiments, a second seal 210b (e.g., an o-ring) is positioned between the site glass 200 and the system adapter 130. The collar body of the device may apply force along the axis of fluid flow forcing the respective collar adapter and system adapter inward towards the site glass and first and/or second seals positioned between the adapters and the site glass (e.g., as depicted in
In some embodiments, the apparatus 100 may include a visual indicator 150. The visual indicator 150 may be positioned in the collar body 110 of the apparatus 100 between the sacrificial anode 140 and the system adapter 130 (e.g., as depicted in
In some embodiments, the apparatus may include a collar adapter and system adapter. The collar adapter may be disposed at the first end 110a of the collar body 110. The system adapter may be coupled to or adjacent the second end 110b of the collar body. In some embodiments, most of the collar adapter may be nested inside the collar body at the first end of the collar body. In some embodiments, the system adapter may be formed as a part of the second end of the collar body of the apparatus. In some embodiments, a portion of the either adapter may extend out of the collar body with outer diameter and depth to allow numerous forms of connection including but not limited to, NPT internal and external, crimped, welded or brazed or barbed (as depicted) for hose and clamps.
In some embodiments, the apparatus may include a elastically compressed member 170 (e.g., as depicted in
In some embodiments, the sacrificial anode 140 may be kept in continuous metallic contact with the noble metal collar adapter 120 of the apparatus 100 by the internal elastically compressed member 170. The elastically compressed member may provide a continuous force on the sacrificial anode acting to maintain direct contact against the collar adapter for continuous positive electric conductivity as the sacrificial anode dissolves and reduces in size. The system adapter may include or be adjacent to a channel 135 which houses the elastically compressed member 170 and visual indicator 150 when the sacrificial anode 140 is compressed against the collar adapter.
In some embodiments, the fluid pressure exerted on the assembly or sacrificial anode 140 which may be configured to contain a restrictive orifice that facilitates hydraulic pressure on the visual indicator 150 and/or the sacrificial anode 140 when the fluid is flowing. The hydraulic force realized may act in combination with the elastically compressed member 170 to ensure continuous electrical contact between the sacrificial anode 140 and the collar adapter 120.
In some embodiments, during use as the sacrificial anode 140 disintegrates, the elastically compressed member 170 expands maintaining force on the sacrificial anode insuring direct contact with the collar adapter 120. The expansion of the elastically compressed member 170 extends along the axis of the site glass 200 and causes a brightly colored indicator 150 connected to the elastically compressed member 170 to progressively fill the view-ports 115 as the sacrificial anode 140 dissolves and the spring expands.
This device described herein provides a continuously visible sacrificial anode that can be inspected while running, without a system interruption or component disassembly. The sacrificial anode is directly visual through the viewports that are incorporated into or as a part of the collar body. The timely replacement of exhausted sacrificial anodes is critical to minimizing the electrolytic corrosion. Viewports in the collar body or transparency of the collar itself, allows for the visibility of the sacrificial anode and/or the visual indicator reaffirms that all components are still being protected from electrolytic corrosion by the sacrificial anode. The device described herein eliminates the time and effort needed to periodically disassemble anode holders for inspection, avoiding hose or piping disassembly for anode inspection, and/or other more cumbersome mechanical methodologies. The visual nature of the device greatly enhances the ease of maintaining the sacrificial anode strategy on components and or systems.
In some embodiments, the collar adapter and the system adapter may be attached to the fluid input or output of the system requiring electrolytic corrosion protection. The apparatus may be attached by any method so long as the anode maintains direct metallic contact with the apparatus. In some embodiments, direct metal contact may be provided by a bonding wire contact 300 from the apparatus to the system requiring protection. Either or both adapters may have a threaded hole (e.g., as depicted in
In some embodiments, the collar adapter or system adapter may include numerous methods of attaching the apparatus 100 to the heat exchanger or system requiring electrolytic corrosion protection. Methods of attaching may include, but are not limited to, brazing, welding, male or female threading (e.g., as depicted in
In this patent, certain U.S. patents, U.S. patent applications, and other materials (e.g., articles) have been incorporated by reference. The text of such U.S. patents, U.S. patent applications, and other materials is, however, only incorporated by reference to the extent that no conflict exists between such text and the other statements and drawings set forth herein. In the event of such conflict, then any such conflicting text in such incorporated by reference U.S. patents, U.S. patent applications, and other materials is specifically not incorporated by reference in this patent.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
This application is a continuation of U.S. patent application Ser. No. 15/641,837 entitled “VISUAL ELECTROLYTIC CORROSION INDICATION AND PREVENTION APPARATUS” filed on Jul. 5, 2017, all of which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15641837 | Jul 2017 | US |
| Child | 16129003 | US |
